Electrical component enclosure with injected seal and method

FIELD OF THE INVENTION

0001The present invention is directed an enclosure with an injected seal for use with an electrical component and method. In particular, the invention is directed to an enclosure with channels to accept the injected seal which is highly compliant and serviceable.

BACKGROUND OF THE INVENTION

0002Sealed connectors or covers are used in many applications to protect the electrical terminals and electrical connections from undesirable or harsh environmental or occupational conditions. Many such connectors or covers use known silicone seals, of for example, 40-60 durometers, which are sensitive to positional and part tolerance variations. Consequently, manufacturing tolerances of the connector or covers must be precisely maintained, adding to the cost of production. In addition, if each connector or cover has multiple configurations, for example different points of exit for the wires or cable, different seals may need to be manufactured to accommodate a proper seal being made.

0003It would, therefore, be beneficial to provide an enclosure which has a channel design in which a highly compliant seal is injected to accommodate various different conductor configurations and positional irregularities.

SUMMARY OF THE INVENTION

0004An embodiment is directed to an enclosure for an electrical component having a base portion and a cover portion. The base portion has a first channel which extends about at least a portion of a periphery of the base portion. The cover portion has a second channel which extends about at least a portion of a periphery of the cover portion. The second channel is aligned with the first channel to form a sealant receiving channel. A sealant is provided in the sealant receiving channel. The cover portion has at least one inlet opening, the inlet opening extends from a top surface of the cover portion to the second channel of the cover. The inlet opening is configured to receive the sealant as the sealant is injected into the sealant receiving channel. The cover portion has at least one outlet opening, the outlet opening is spaced from the inlet opening and extends from a top surface of the cover portion to the second channel of the cover portion. The outlet opening is configured to allow excess sealant of the sealant to escape from the sealant receiving channel as the sealant is injected into the sealant receiving channel.

0005An embodiment is directed to a method of providing a sealant to an enclosure. The method comprising: mating a base portion of the enclosure with a cover portion of the enclosure, the base portion having a first channel and the cover portion having a second channel, the first channel and the second channel forming a sealant receiving channel; injecting sealant through at least one inlet opening in the cover into the sealant receiving channel; flowing the sealant from the at least one inlet opening through the sealant receiving channel to at least one outlet opening; and flowing excess sealant from the at least one outlet opening.

0006Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

0007<figref idref="DRAWINGS">FIG. 1</figref> is a top perspective of an illustrative embodiment of an enclosure device of the present invention.

0008<figref idref="DRAWINGS">FIG. 2</figref> is a bottom perspective of the enclosure device of <figref idref="DRAWINGS">FIG. 1</figref>.

0009<figref idref="DRAWINGS">FIG. 3</figref> is a perspective view of the enclosure device of <figref idref="DRAWINGS">FIG. 1</figref> with a cover portion open relative to a base portion.

0010<figref idref="DRAWINGS">FIG. 4</figref> is a top view of the enclosure device showing the cover portion and the base portion in an open position.

0011<figref idref="DRAWINGS">FIG. 5</figref> is a cross-section view of the enclosure device taken along line <b>5</b>-<b>5</b> of <figref idref="DRAWINGS">FIG. 1</figref>.

0012<figref idref="DRAWINGS">FIG. 6</figref> is a top perspective of the enclosure device of <figref idref="DRAWINGS">FIG. 1</figref> with sealing gel provided therein.

0013<figref idref="DRAWINGS">FIG. 7</figref> is a cross-section view of the enclosure device taken along line <b>7</b>-<b>7</b> of <figref idref="DRAWINGS">FIG. 6</figref>.

DETAILED DESCRIPTION OF THE INVENTION

0014The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

0015Moreover, the features and benefits of the invention are illustrated by reference to the preferred embodiments. Accordingly, the invention expressly should not be limited to such embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features, the scope of the invention being defined by the claims appended hereto.

0016As shown in <figref idref="DRAWINGS">FIGS. 1-3</figref>, a cover or enclosure device <b>10</b> for use with an electrical component has a cover portion <b>12</b> and a base portion <b>14</b>. In the illustrative embodiment shown, a hinge portion <b>16</b> is provided to allow the cover portion <b>12</b> to move between an open position and a closed position relative to the base portion <b>14</b>. The enclosure device <b>10</b> is positioned on an electrical component (not shown) to provide a sealed entrance for wires or cables.

0017As shown in <figref idref="DRAWINGS">FIGS. 3 and 4</figref>, the base portion <b>14</b> has a first or front wall <b>20</b> with a seal receiving section <b>22</b>. The seal receiving section <b>22</b> has conductor receiving cavities <b>24</b> extending therethrough. A second or rear wall <b>26</b> is positioned opposite the front wall <b>20</b>. Hinge members <b>27</b> extend from the rear wall <b>26</b>. Side walls <b>28</b>, <b>30</b> extend between the front wall <b>20</b> and the rear wall <b>26</b>. In the illustrative embodiment shown, the front wall <b>20</b>, rear wall <b>26</b> and side walls <b>28</b>, <b>30</b> form a rectangular configuration, however, other configurations may be used. The base portion <b>14</b> has an opening <b>32</b> which is provided on the bottom (as viewed in <figref idref="DRAWINGS">FIGS. 3 and 4</figref>). The opening <b>32</b> is open to the electrical component when the enclosure device <b>10</b> is positioned on the electrical component.

0018As shown in <figref idref="DRAWINGS">FIGS. 3 and 4</figref>, a first seal <b>36</b> is provided in the seal receiving section <b>22</b> of the front wall <b>20</b> of the base portion <b>14</b>. The seal <b>36</b> has conductor receiving openings <b>38</b> (<figref idref="DRAWINGS">FIG. 3</figref>) for receipt of conductors, such as cables (not shown). Ribs or ridges <b>39</b> are provided on the outside edges of the seal <b>36</b>. The first seal <b>36</b> is made from a material, such as, but not limited to rubber, which can deform or compress as the cover portion <b>12</b> and base portion <b>14</b> are mated together to provide proper sealing.

0019A first or lower seal receiving channel or recess <b>34</b> is provided on the rear wall <b>26</b> and side walls <b>28</b>, <b>30</b>. The seal receiving recess <b>34</b> extends about the periphery of the rear wall <b>26</b> and side walls <b>28</b>, <b>30</b> and is open in a direction extending toward the cover portion <b>12</b>.

0020The cover portion <b>12</b> has a first or front wall <b>40</b> with a seal receiving section <b>42</b>. The seal receiving section <b>42</b> has conductor receiving cavities <b>44</b> extending therethrough. A second or rear wall <b>46</b> is positioned opposite the front wall <b>40</b>. Hinge members <b>47</b> extend from the rear wall <b>46</b>. Side walls <b>48</b>, <b>50</b> extend between the front wall <b>40</b> and the rear wall <b>46</b>. In the illustrative embodiment shown, the front wall <b>40</b>, rear wall <b>46</b> and side walls <b>48</b>, <b>50</b> form a rectangular configuration, however, other configurations may be used. The cover portion <b>12</b> has a top surface <b>52</b>.

0021A second or upper seal receiving channel or recess <b>54</b> is provided on the rear wall <b>46</b> and side walls <b>48</b>, <b>50</b>. The seal receiving recess <b>54</b> extends about the periphery of the rear wall <b>46</b> and side walls <b>48</b>, <b>50</b> and is open in a direction extending toward the base portion <b>14</b>. A wall or projection <b>60</b> extends from the cover portion <b>12</b> into the seal receiving recess <b>54</b>, as shown in <figref idref="DRAWINGS">FIGS. 5 and 7</figref>. The wall <b>60</b> provides alignment and an enhanced seal as will be more fully described.

0022As shown in <figref idref="DRAWINGS">FIGS. 1 and 6</figref>, mounting openings <b>62</b> extend through the cover portion <b>12</b> proximate the seal receiving section <b>42</b>. The mounting openings <b>62</b> align with mounting openings <b>64</b> provided in the base portion <b>14</b> to accept mounting hardware (not shown) to secure the cover portion <b>12</b> to the base portion <b>14</b> when the enclosure device <b>10</b> is fully assembled.

0023A seal injection or inlet opening <b>66</b> is provided in the cover portion <b>12</b>. In the illustrative embodiment shown, the seal inlet opening <b>66</b> is provided proximate the rear wall <b>46</b> of the cover portion <b>12</b>. However, other positions of the seal inlet opening <b>66</b> may be used without departing from the scope of the invention. As shown in <figref idref="DRAWINGS">FIG. 5</figref>, the seal inlet opening <b>66</b> is provided in line with the upper seal receiving recess <b>54</b>. The seal inlet opening <b>66</b> extends to either side of the wall <b>60</b>.

0024Seal exit or outlet openings <b>68</b> are provided in the cover portion <b>12</b>. In the illustrative embodiment shown, the seal outlet openings <b>68</b> are provided proximate the front wall <b>40</b> and proximate the seal receiving section <b>42</b> of the cover portion <b>12</b>. However, other positions of the seal outlet opening <b>68</b> may be used without departing from the scope of the invention. The seal outlet openings <b>68</b> are provide in line with the upper seal receiving recess <b>54</b>. The seal outlet openings <b>68</b> extend to either side of the wall <b>60</b>.

0025In use, the base portion <b>14</b> is assembled or adhered to the electrical component, such as an electrical connector, circuit board or the like. Conductors, such as cables or wires (not shown), are inserted through conductor receiving openings <b>38</b> of the seal <b>36</b> and are terminated to the electrical component. The seal <b>36</b> is positioned in the seal receiving section <b>22</b> of the base portion <b>14</b> and the conductor are positioned in the conductor receiving cavities <b>24</b>.

0026With the conductors properly terminated and the seal <b>36</b> properly positioned in the seal receiving section <b>22</b> of the base portion <b>14</b>, the cover portion <b>12</b> is rotated about the hinge portion <b>16</b> from an open position, as illustrative shown in <figref idref="DRAWINGS">FIG. 3 or 4</figref>, to a closed position, as shown in <figref idref="DRAWINGS">FIGS. 1, 2 and 5</figref>. In the closed position, the seal <b>36</b> is positioned in the seal receiving section <b>42</b> of the cover portion <b>12</b> and the conductor are positioned in the conductor receiving cavities <b>44</b>. With the cover portion <b>12</b> properly positioned on the base portion <b>14</b>, mounting hardware (not shown) is inserted into the mounting openings <b>62</b> of the cover portion <b>12</b>, the mounting openings <b>64</b> of the seal <b>36</b> and the mounting openings (not shown) of the base portion <b>14</b> to secure the cover portion <b>12</b> to the base portion <b>14</b>.

0027With the cover portion <b>12</b> properly secured to the base portion <b>14</b>, the lower seal receiving recess <b>34</b> and the upper seal receiving recess <b>54</b> align to form a combined seal receiving recess <b>70</b> which extends about the periphery of the enclosure device <b>10</b>. With the combined seal receiving recess <b>70</b> properly formed a sealant gel <b>72</b>, <figref idref="DRAWINGS">FIGS. 6 and 7</figref>, is injected into the seal inlet opening <b>66</b> of the cover portion <b>12</b>. The sealant gel <b>72</b>, may be, but is not limited to, a soft silicone based gel which is designed to conform to its surrounding with minimal force and provide a watertight seal for low voltage (less than 1000 volts) electrical applications.

0028In an illustrative embodiment, the sealant gel <b>72</b> does not require heating or curing, does not flow or leak over time, and is re-enterable or resealable. The sealant gel <b>72</b> may be cross linked and cold applied. The thermal resistance of the sealant gel <b>72</b> may be half of the thermal resistance of elastomers, thereby minimizing or eliminating interfacial resistance. In addition, illustrative sealant gel <b>72</b> may provide a 30-50 degree Celsius reduction in junction temperature when compared to an elastomer pad. The sealant gel <b>72</b> provides design flexibility and robustness, as the sealant gel <b>72</b> have a 3-5 times higher compressibility versus soft elastomers.

0029As the sealant gel <b>72</b> is injected into the seal inlet opening <b>66</b>, the sealant gel <b>72</b> if forced into the combined seal receiving recess <b>70</b>. As this occurs, the sealant gel <b>72</b> flows around the projection <b>60</b>, thereby providing an increased surface area for the sealant gel <b>72</b> to engage and seal to the projection <b>60</b>. Continued injection of the sealant gel <b>72</b> forces the sealant gel <b>72</b> to flow through the combined seal receiving recess <b>70</b> to the seal outlet openings <b>68</b> (<figref idref="DRAWINGS">FIG. 1</figref>), which may cause the sealant gel <b>72</b> to flow out of the seal outlet opening, as represented by the sealant get <b>72</b> shown in <figref idref="DRAWINGS">FIG. 6</figref>. In addition, the sealant gel <b>72</b> may be forced into between the ridges <b>39</b> of the seal <b>36</b>.

0030Injection of the sealant gel <b>72</b> is stopped once sealant gel <b>72</b> is visible or extend from each of the seal outlet openings <b>68</b>. The seal outlet openings <b>68</b> provide an exit or outlet for the sealant gel <b>72</b>, thereby allowing the sealant gel <b>72</b> to flow easily through the combined seal receiving recess <b>70</b> without encountering pressure build up or the like. In addition, the flow of the sealant gel <b>72</b> from the seal outlet openings <b>68</b> provides a visible indication to the operator that the combined seal receiving recess <b>70</b> is fully filled and that the sealant gel <b>72</b> has provided a proper seal between the cover portion <b>12</b> and the base portion <b>14</b>.

0031The use of the lower seal receiving recess or channel <b>34</b> on the base portion <b>14</b> and the upper seal receiving recess or channel <b>54</b> on the cover portion <b>12</b> to form the combined seal receiving recess or channel <b>70</b> allows for the cover portions <b>12</b> to be mated to the base portion <b>14</b> even if there are small tolerance inconsistencies or positional irregularities. The projection <b>60</b> is positioned within the lower seal receiving recess or channel <b>34</b> on the base portion <b>14</b> to properly align the cover portion <b>12</b> with the base portion <b>14</b>. However, as the projection <b>60</b> can be provided anywhere within the lower seal receiving recess or channel <b>34</b>, precise alignment of the cover portion <b>12</b> with the base portion <b>14</b> is not required. The injection of the sealant gel <b>72</b> into the combined seal receiving recess or channel <b>70</b> provides proper sealing of between the cover portion <b>12</b> and the base portion <b>14</b> regardless of the positioning of the of the projection <b>60</b> in the lower seal receiving recess or channel <b>34</b>. In addition, the use of the sealant gel <b>72</b> into the combined seal receiving recess or channel <b>70</b> allows for the serviceability of the electrical component, as the cover portion <b>14</b> may be opened and reused by refilling the combined seal receiving recess or channel <b>70</b> with additional sealant gel <b>72</b>.

0032While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention as defined in the accompanying claims. One skilled in the art will appreciate that the invention may be used with many modifications of structure, arrangement, proportions, sizes, materials and components and otherwise used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being defined by the appended claims, and not limited to the foregoing description or embodiments.